Miller Electric OM-230 manual

Processes Description MIG (GMAW ) W elding Flux Cored (FCAW ) W elding Arc Welding Power Source and Wire Feeder OM-230 693C 2007−11 Millermatic 252 R File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 8 − MIG WELDING (GMA W) GUIDELINES 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical MIG Process Connections 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. T ypical MIG Process Control Settin[...]

OM-230 693 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols o[...]

OM-230 693 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

OM-230 693 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

OM-230 693 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and [...]

OM-230 693 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves[...]

OM-230 693 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

OM-230 693 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

OM-230 693 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de t o ucher[...]

OM-230 693 Page 9 2-5. P ri nc ipa le s no rm es d e s écu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American[...]

OM-230 693 Page 10[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Wire Feed Output X Duty Cycle Do Not Switch While W elding V V olts Increase On Of f Gas Metal Arc W elding (GMA W) Gun Wire Feed Spool Gun Gas Input Gas Output V oltage Input Press T o Reset U 0 Rated No-Load V o[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 12 4-2. W elding Power Source Duty Cycle And Overheating 4 Minutes W elding 6 Minutes Resting 6 Minutes W elding 4 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, Thermistor (T) opens, output [...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 13 4-4. Connecting T o Weld Output T erminals 803 778-A ! T urn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat an d start a fire, or damage your ma- chine. 1 Weld Output T erminal 2 Supplied Weld Ou[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 14 4-6. Connecting Spoolmatic ) 15A Or 30A Gun 804 910-A 1 Gu n Trigger Plug Insert plug into receptacle, and tighten threaded collar . 2 Weld Cable 3 Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel. 4 Positive Weld Outp[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 15 4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python Ref. 804 910-A / 804 936-A . XR E dge guns p rior to serial n o. LE079101 require an a dapter cor d (par t no. 195 498) . 1 Gun End 2 Gun Liner 3 Wire Outlet Guide T rim excess liner from end of gun so no [...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 16 4-8. Setting Gun Polarity For Wire T ype 1 Polarity Changeover Label Information Always read and follow manufacture’s recommended polarity . 1 3/4, 1 1/16 in Ref. 190 821-A Changing Polarity D D Wire Drive Assembly Lead Work Clamp Lead + Positive T erminal Shown as s[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 17 4-10. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. T ools Needed: 072573-B / 802 922 Installing 1 Or 2 lb Wire Spool T o install either a 1 lb or[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 18 4-12. Electrical Service Guide Failure to fo llow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power sou[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 19 4-13. Selecting A Location And Connecting Input Power 804 912-A L1 L2 230 V AC, 1 18 in (457 mm) of space for airflow ! Do not move or operate unit where it could tip. 3 ! Installation must meet all National an d Local Codes − have only qualified persons make this in[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 20 4-14. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. T ools Needed: 6 in (150 mm) . Hold wire tightly to keep it from unr aveling. WOOD Op[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 21 Notes[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 22 4-15. W eld Parameters[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 23 226 650-B[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 24 SECTION 5 − OPERA TION 5-1. Controls 226 647-B 1 V oltage Control Turn control clockwise to increase voltage. 2 Wire Speed Control Turn control clockwise to increase wire feed speed. 3 V oltmeter 4 Wire Feed Speed Meter 2 3 . This unit has three automatic timers incl[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 25 JOG Mode If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatically shut off weld power (and shielding gas output on MIG gun only), but will feed wire continuously at the preset wire feed speed (which may be faster[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 26 5-2. V oltmeter And Wire Feed Speed Meter Operation 1 V oltmeter 2 Wire Feed Speed Meter Power Up Status Both meters display 888 at unit power up. After 0.5 seconds, preset values appear on both meters. The settings for the last active gun used will be the default at i[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 27 5-4. Timers 1 V oltage Control 2 Wire Speed Control 3 V oltmeter 4 Wire Feed Speed Meter T o enter the TIMERS menu press and hold the gun trigger while turning on the power switch until the left meter displays (run), then release trigger . Once in the TIMERS menu, rota[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 28 . W elding wire birdnesting at the welding power source drive rolls may occur if this value is set too high. 5-5. Set Up Push Motor T orque (SUP) Or Reset (rES) 1 V oltage Control 2 Wire Speed Control 3 V oltmeter 4 Wire Feed Speed Meter Depress the gun trigger while t[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 29 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 30 6-4. Aligning Drive Rolls and Wire Guide ! T urn Off power . V iew is from top of drive rolls looking down with pressure assembly open. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver , and turn screw in or out until d[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 31 6-5. T roubleshooting T rouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13 ). Replace building line fuse or reset circuit breaker if open (see Section 4-13 ). Secure gun trigger connections (see welding gun Owner’[...]

. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 32 T rouble Remedy No wire feed. Turn Wire Speed control to higher setting (see Section 5-1 ). Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual). Readjust drive roll pressure (see Section 4-14 ). Change to correct size drive rolls (see Secti[...]

OM-230 693 Page 33 Notes[...]

OM-230 693 Page 34 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram[...]

OM-230 693 Page 35 229 485-A[...]

OM-230 693 Page 36 SECTION 8 − MIG WELDING (GMA W) GUIDELINES 8-1. T ypical MIG Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl a c e w o r k c l a m p a s close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Sh[...]

OM-230 693 Page 37 8-2. T ypical MIG Process Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. 1/8 or .125 in Material thickness determines weld parameters. Convert Material (.001 in = 1 ampere) .12[...]

OM-230 693 Page 38 8-3. Holding And Positioning Welding Gun . W elding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger , be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4 Electrode[...]

OM-230 693 Page 39 8-4. Conditions That Affect Weld Bead Shape . Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (STICKO[...]

OM-230 693 Page 40 8-5. Gun Movement During Welding . Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Alon[...]

OM-230 693 Page 41 8-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long.[...]

OM-230 693 Page 42 8-1 1. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintai[...]

OM-230 693 Page 43 8-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support h[...]

OM-230 693 Page 44 8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Gas Spray Arc Steel Short Circuiting Steel Short Cir[...]

OM-230 693 Page 45 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed o n welding power [...]

OM-230 693 Page 46 SECTION 9 − P ARTS LIST 9-1. Drive Roll And Wire Guide Kits . Base selection of drive rolls upon the following recommended usages: 1 V -Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V -Knurled rolls for ha[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expert[...]

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